Pump diaphragm rupture detection

ABSTRACT

A hydraulically driven pump includes a first chamber exposed to a process fluid, a second chamber configured to retain a hydraulic fluid, and a multi-layer diaphragm positioned between the first and second chambers. The diaphragm includes a first layer in contact with the process fluid being pumped, a second layer in contact with the hydraulic fluid, and a third layer that includes an elastomeric base material and an elastomeric conductive trace embedded in the elastomeric base material. The third layer is positioned between the first and second layers and being movable relative to the first and second layers. Changes in an electrical resistance of the conductive trace indicate a failure condition in one of the first, second and third layers.

This application is a continuation of U.S. application Ser. No.10/726,984, filed Dec. 2, 2003.

BACKGROUND OF THE INVENTION

1. Technical Field

The invention generally relates to hydraulically driven pumps, and morespecifically relates to diaphragms for hydraulically driven pumps.

2. Related Art

The known rotary-operated, oil-backed/driven diaphragm pump is ahigh-pressure pump inherently capable of pumping many difficult fluidsbecause in the process fluid, it has no sliding pistons or seals toabrade. The diaphragm isolates the pump completely from the surroundingenvironment (the process fluid), thereby protecting the pump fromcontamination.

In general, a diaphragm pump 20 is shown in FIGS. 9 and 10. Pump 20 hasa drive shaft 22 rigidly held in the pump housing 24 by a large taperedroller bearing 26 at the rear of the shaft and a small bearing (notshown) at the front of the shaft. Sandwiched between another pair oflarge bearings (not shown) is a fixed-angle cam or wobble plate 28. Asthe drive shaft turns, the wobble plate moves, oscillating forward andback converting axial motion into linear motion. The three pistonassemblies 30 (only one piston assembly is shown) are alternatelydisplaced by the wobble plate 28. As shown later, each piston is in anenclosure including a cylinder such that the enclosure is filled withoil. A ball check valve 32 in the bottom of the piston/cylinder assembly30 functions to allow oil from a reservoir 27 (wobble plate 28 is in thereservoir) to fill the enclosure on the suction stroke. During theoutput or pumping stroke, the held oil in the enclosure pressurizes theback side of diaphragm 34 and as the wobble plate moves, causes thediaphragm to flex forward to provide the pumping action. Ideally, thepump hydraulically balances the pressure across the diaphragm over thecomplete design pressure range. As discussed later, in actual practicethis is not the case for all situations for known pumps. In any case,each diaphragm has its own pumping chamber that contains an inlet and anoutlet check valve assembly 36, 37. As the diaphragm retracts, processfluid enters the pump through a common inlet and passes through one ofthe inlet check valves. On the output or pumping stroke, the diaphragmforces the process fluid out the discharge check valve and through themanifold common outlet. The diaphragms, equally spaced 120° from oneanother, operate sequentially to provide constant, virtually pulse-freeflow of process fluid.

The diaphragm 34 is held between two portions 38, 40 of housing 24.Diaphragm 34 separates the pump side from the oil-filled, hydraulicdrive side of the pump. On the drive side, a drive piston assembly 30including a diaphragm plunger 42 is contained within the oil filledenclosure which functions as a transfer chamber 44. A pair of checkvalves 32 in piston 46 separate transfer chamber 44 from the oilreservoir (not shown). Wobble plate 28 (not shown in FIG. 2) contactspad 48 to drive piston 46. Arrow 49 indicates the general direction ofmovement of the cam or wobble plate. When the piston and diaphragm havefinished the forward or pumping stroke, the end 50 of piston 46 is attop dead center (TDC). When the piston and diaphragm have retracted inthe suction stroke, the end 50 of piston 46 is at bottom dead center(BDC).

FIGS. 11( a)-(f) illustrate operation of the conventional pump 20 undernormal, standard operating conditions using a conventional bias spring96. Typical pressures are shown. Typical vector directions for the camor wobble plate (not shown in FIGS. 11( a)-(f) are shown. Suction isless than 14.7 psia. Output pressure is greater than 14.7 psia. Thepressure differential across diaphragm 34 is set at about 3 psia.

With reference to FIG. 11( a), the suction stroke begins at the end ofthe pumping stroke. For the conditions assumed, pressure in the pumpingchamber immediately drops from what it was at high pressure, forexample, 120 psia to 10 psia. Pressure in the hydraulic transfer chamberis 13 psia, which is less than the 14.7 psia in the reservoir. Thepiston 30 is at top dead center and begins moving toward bottom deadcenter. Bias spring 96 momentarily moves plunger 42, and particularlyvalve spool 84, to the right to open port 98. Because pressure in thetransfer chamber is less than the pressure in the reservoir, check valve46 opens and oil flows from the reservoir to the transfer chamber toappropriately fill it with oil that had been lost during the pumpingstroke previous. That is, under the pressure of the pumping stroke oilflows through somewhat loose tolerances of the parts of the piston sothat the some oil flows from the transfer chamber back to the reservoir.Thus oil needs to be refilled in the transfer chamber during the suctionstroke so that there is enough oil to efficiently provide pressureduring the next pumping stroke.

FIG. 11( b) shows the configuration at mid-stroke. The slight suction inthe pumping chamber (shown to be 10 psia), holds diaphragm 34 and spool84 to the left while piston 30 moves to the right, thereby shutting offport 98. Since pressures are nearly equal and diaphragm 34 moves rightwith piston 30, the pumping chamber fills with process fluid.

As shown in FIG. 11( c), process fluid continues to fill as diaphragm 34moves right. Valve port 98 remains shut. Very little leakage of oiloccurs from the reservoir (not shown) to transfer chamber 44, sincepressures are nearly equal. Thus, both sides of the diaphragm fillproperly.

When piston 30 reaches bottom dead center, the suction stroke iscompleted and the output or pumping stroke begins. Pressure in thetransfer chamber immediately increases, for example, from 13 psia to 123psia. Likewise, pressure in the pumping chamber immediately increases,for example, from 10 psia to 120 psia. The wobble plate begins movingpiston 30 to the left, which causes the build-up of pressure. Checkvalves 32 close. Diaphragm 34 moves in volume tandem with the oil andprocess fluid left with the piston to push (pump) process fluid out.

At mid-stroke as shown in FIG. 11( e), there is continued output. Someoil leakage past the tolerances between piston and cylinder may movevalve spool 84 of diaphragm plunger 42 to the right to open valve port98. Check valves 32, however, are closed, thereby locking the oil intransfer chamber 44, except for leakage.

The output stroke finishes with the configuration shown in FIG. 11( f).The filled transfer chamber 44 pushes diaphragm 32 to the leftdispensing process fluid as it moves. Normal operation as shown in FIGS.11( a)-(f) causes little stress on diaphragm 32.

Piston 46 reciprocates in cylinder 47. Piston 46 has a sleeve section 52that forms the outer wall of the piston. Sleeve section 52 includes asleeve 54 and an end portion 56 at the end having pad 48 that is contactwith the wobble plate. Within sleeve 54 is contained a base section 58.Base section 58 includes a first base 60 that is in contact with endportion 56 and includes seal elements 62 for sealing between first base60 and sleeve 54. Base section 58 also includes second base 64 at theend opposite of first base 60. Connecting wall 66 connects first andsecond bases 60 and 64. Piston return spring 68 is a coil spring thatextends between first base 60 and diaphragm stop 70, which is a part ofthe pump housing 24. Valve housing 72 is contained within base section58 and extends between second base 64 and end portion 56. Seals 74provide a seal mechanism between valve housing 72 and connecting wall 66near second base 64.

The end 76 opposite end portion 56 of sleeve portion 52 is open.Likewise, the end 78 of valve housing 72 is open. Second base 64 has anopening 80 for receiving the stem 82 of plunger 42.

Diaphragm plunger 42 has the valve spool 84 fitted within valve housing72 with the stem 82 extending from the valve spool 84 through opening 80to head 86 on the transfer chamber side of diaphragm 34. Base plate 88is on the pumping chamber side of diaphragm 34 and clamps the diaphragmto head 86 using a screw 90 which threads into the hollow portion 92 ofplunger 42. Hollow portion 92 extends axially from one end of plunger 42to the other end. Screw 90 is threaded into the diaphragm end. Thepiston end of hollow portion 92 is open. A plurality of radiallydirected openings 94 are provided in stem 82. A bias spring 96 is a coilspring and extends between second base 64 and valve spool 84. A valveport 98 is provided in the wall of valve housing 72. A groove 100extends in connecting wall 66 from the furthest travel of valve port 100to end portion 56. A check valve 102 is formed in end portion 56 in apassage 104, which is fluid communication with the reservoir (notshown). Thus, there is fluid communication from the reservoir (notshown) through passage 104 and check valve 102 via groove 100 to valveport 98. When the valve is open, there is further communication throughthe space in which coil spring 96 is located and then through one of theplurality of radial openings 94 and through the axial hollow portion 92of plunger 84. There is further fluid communication from the hollowportion 92 through the other radially directed openings 94 to variousportions of transfer chamber 44. The hollow passage 92, along with theradially directed openings 94 provide fluid communication from theportion of transfer chamber 44 near diaphragm 34 to the portion oftransfer chamber 44 within the valve housing 72 of piston 30. Thetransfer chamber also includes the space occupied by piston returnspring 68.

On the pump side of diaphragm 34, there is an inlet check valve assembly36 which opens during the suction stroke when a vacuum is created inpumping chamber 106. There is also a check valve 37 that opens duringthe pumping or output stroke when pressure is created in pumping chamber106.

A problem with conventional diaphragm pumps, however, is an unexpecteddiaphragm rupture under certain operating conditions. The diaphragm canfail much sooner than normal, or more frequently, may fail sooner thanother pump components. A failure contaminates the process lines withdrive oil. The operating condition that most often causes failure is ahigh vacuum inlet with a corresponding low outlet pressure. This is anexpected occurrence in a typical pumping system when the inlet filterbegins to plug. In that case, the plugging requires high vacuum to nowpull process fluid through the filter. At the same time, the lowering ofprocess fluid volume pumped drops the outlet pressure. This creates asituation where a high suction on the pumping side lowers the pressureduring the suction stroke on the transfer chamber side so that thetransfer chamber essentially “asks for more fill fluid” and,consequently, in-flowing oil overfills the transfer chamber and does sowithout a corresponding high pressure to push oil out during the pumpingor output stroke to counter-balance. The overfill of oil “balloons” thediaphragm into the fluid valve port until the diaphragm tears.Additionally, with a high-speed, reversing, vacuum/pressure pump such asthis apparatus, the high-speed valve closings create tremendous pressurespikes, called Joukobski shocks. The spikes can consist of fluidpressure or acoustical waves and harmonics of both. These pressurespikes can “call for” oil fluid flow into the drive piston when thatshould not be happening. Again, this can cause overfill and lead to thediaphragm failure.

Because of the possibility of diaphragm rupture, hydraulically drivenpumps are typically unsuitable for many applications that cannottolerate this type of contamination, such as, for example, spray paintlines. Except for the possibility of contamination due to a ruptureddiaphragm, hydraulically driven pumps would be a preferred choice ofpumps for many applications. Therefore, there is a need to be able todetect when a diaphragm fails and use that information to shut down thepump.

Various methods for detecting diaphragm rupture have been employed inthe past. One example diaphragm rupture detection system includes theuse of two diaphragms that have a vacuum between them, as disclosed inU.S. Pat. No. 5,667,368. This method requires the use of complicatedhardware for maintaining a vacuum and detecting the loss of vacuum.

Another diaphragm rupture detection method uses two diaphragms that areseparated by a liquid. This method, as disclosed in U.S. Pat. No.4,971,523, includes detecting a change in the electrical conductivity ofthe liquid. This method further requires that the properties of theliquid are different from the pumped fluid so that a change can bedetected in the event of a rupture. Thus, a requirement of this methodis that intermediate fluid is different than the pumped fluid and thepump oil, which intermediate fluid may have to be changed depending onthe conductivity of the pumped fluid.

Another method of diaphragm rupture detection is disclosed in U.S. Pat.No. 4,781,535. This method uses a continuous metal trace formed on thesurface of a diaphragm. The trace is monitored for continuity as well asground fault to the pumped liquid. The ground fault detection is toguard against breakage being masked by the conductivity of the fluid,which would otherwise bridge the conductive trace. Since the trace isrequired to be metallic, the trace will break if it is exposed to anysignificant strain. This system enables the use of a metal trace byminimizing the strain through the use of complex trace shapes. U.S. Pat.No. 4,781,535 illustrates several example low deflection, large diameterdiaphragms that have relatively low strain.

SUMMARY OF THE INVENTION

The present invention generally relates to hydraulically driven pumpsthat include a diaphragm. The diaphragm of the present inventionincludes multiple elastomeric layers with an elastomeric conductivetrace embedded in one of the layers. Although the layers may be bondedto each other, in a preferred embodiment the layers are independentlymovable relative to each other so that wear and fail of each layeroccurs independently.

One aspect of the invention relates to a multi-layer diaphragm for usein a hydraulically driven pump. The diaphragm includes a first layer incontact with a pumped process fluid, a second layer in contact with ahydraulic fluid of the pump, and a third layer made of an elastomericmaterial that includes an elastomeric conductive trace embedded in theelastomeric material. The third layer is positioned between the firstand second layers and is independently movable relative to the first andsecond layers.

Another aspect of the invention relates to a method of manufacturing apump diaphragm that includes an elastomeric layer and a conductivetrace. The method includes forming a first portion of the elastomericlayer, forming the conductive trace on a primary surface of the firstportion of the elastomeric layer, and forming a second portion of theelastomeric layer on the primary surface of the first portion over aportion of the conductive trace such that the first and second portionsare integral with each other and an outer periphery of the conductivetrace is exposed. The conductive trace includes an elastomeric materialsuch as a mixture of silicone and carbon that is resistant to straincondition of at least 20% and is electrically conductive.

A further aspect of the invention relates to a method of detectingrupture of a diaphragm in a hydraulic pump that includes a first, secondand third elastomeric layers. The third layer includes an elastomericmaterial such as silicone and an elastomeric conductive trace embeddedin the elastomeric material The method includes positioning the firstlayer in contact with a fluid being pumped by the hydraulic pump,positioning the second layer in contact with a hydraulic fluid of thehydraulic pump, positioning the third layer between the first and secondlayers, applying an electric current to the conductive trace, detectingvariations in electrical resistance resulting from use of the diaphragmin the hydraulic pump, and generating a detection signal, and shuttingoff the hydraulic pump when the detection signal is within apredetermined range.

A yet further aspect of the invention relates to a multi-layer diaphragmfor use in a hydraulically driven pump that includes a first layerhaving a first modulus of elasticity, a second layer having a secondmodulus of elasticity, and a third layer positioned between the firstand second layers and having a third modulus of elasticity lower thanthe first and second modulus of elasticity. The diaphragm also includesan elastomeric conductive trace integral with the third layer andexposed at an outer periphery of the third layer at a location removedfrom contact with fluids in the pump.

Another aspect of the invention relates to a hydraulically driven pumpthat includes a first chamber exposed to a process fluid, a secondchamber configured to retain a hydraulic fluid, and a multi-layerdiaphragm positioned between the first and second chambers. Thediaphragm includes a first layer in contact with the process fluid, asecond layer in contact with the hydraulic fluid, and a third layer thatincludes an elastomeric material such as silicone and an elastomericconductive trace embedded in the elastomeric material. The third layeris preferably positioned between the first and second layers and ispreferably independently movable relative to the first and secondlayers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of one example pump that includes adiaphragm assembly according to principles of the present invention;

FIG. 2 is a front perspective view of the diaphragm assembly shown inFIG. 1;

FIG. 3 is a rear perspective view of the diaphragm assembly shown inFIG. 1;

FIG. 4 is an exploded front perspective view of the diaphragm assemblyshown in FIG. 1;

FIG. 5 is a an exploded rear perspective view of the diaphragm assemblyof FIG. 1;

FIG. 6 cross-sectional view of the diaphragm assembly shown in Figure 2taken along cross-sectional indicators 6-6;

FIG. 7 is an exploded view of the cross-sectional view shown in FIG. 6;

FIG. 8 is a rear plan view of one of the diaphragm layers shown in FIG.4 having an example conductive trace pattern formed thereon according toprinciples of the present invention;

FIG. 9 is a perspective view of a conventional diaphragm pump; and

FIG. 10 is a partial cross-sectional view of the conventional diaphragmpump shown in FIG. 9.

FIGS. 11( a)-(f) illustrate operation of the conventional pump undernormal, standard operating conditions using a conventional bias spring.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention generally relates to a diaphragm for ahydraulically driven pump that is an improvement to the conventionaldiaphragms described above. Like parts are designated by like numerals.Improved parts are distinguished and described. The invention generallyrelates to hydraulically driven pumps, and more specifically relates todiaphragms for hydraulically driven pumps and the detection of failurein such diaphragms. The diaphragm includes at least three elastomericlayers made of high strain resistant materials. The layer positionedbetween the other two layers includes a conductive trace embeddedtherein. Changes in the conductive trace resistance is monitored whilethe diaphragm is in use. When the resistance values reach a certainpredetermined level that indicates failure in one or more of thediaphragm layers, or the possibility of a failure occurring, a failuresignal is generated. A rupture of the middle layer will also be detectedsince a break in the conductive trace would cause an open circuit, whichwould exceed the predetermined resistance level. The failure signal maybe used to shut off the pump, thereby preventing mixing of the hydraulicfluid on one side of the diaphragm with the process fluid being pumpedon the other side of the diaphragm within the pump.

Preferably, the layers of the diaphragm are not bonded together suchthat they are independently movable when the diaphragm is deformedduring flexing. When the layers are separate from each other, there is areduced likelihood that a rupture in one layer will propagate to theadjoining layer. As a result, a failure in one layer of the diaphragmcan be detected and the pump shut down before all of the layers fail.

As used in here the term “modulus of elasticity” is defined as the ratioof the increment of some specified form of stress to the increment ofsome specified form of strain, such as Young's Modulus, the bulkmodulus, or the shear modulus. The term “elastomer” or “elastomeric” isdefined as a polymeric material, such as a synthetic rubber or plastic,which at room temperature can be stretched under low stress to at leasttwice its original length and, upon immediate release of the stress,will return with force to its appropriate original length.

An example of diaphragm pump 120 utilizing a diaphragm 122 according toprinciples of the invention is shown in FIG. 1. Pump 120 includes afirst chamber 124 exposed to the process fluid being pumped, and asecond chamber 126 that retains hydraulic fluid. The diaphragm 122 ispositioned between the first and second chambers 124, 126 and issealably secured within the pump to provide a sealed interface betweenthe hydraulic fluid and the process fluid. Outside of the diaphragm 122,pump 120 includes features and functionality that corresponds with knowndiaphragm pumps as described in the Background section above.

Diaphragm 122 includes first layer 140, second layer 142, and a middleor third layer 144, as shown in FIGS. 1-7. A conductive trace 150 isformed on a primary surface of third layer 144 (see the exampleconductive trace pattern shown formed on third layer 144 in FIG. 8). Thelayers 140, 142, 144 may be retained together with first and second rimmembers 152, 154 that, when secured together, create a packaged assemblythat is relatively easy to handle for transportation and installationpurposes. The use of a rim to retain the diaphragm layers isparticularly useful when the diaphragm layers are not bonded togethersuch that they are independently movable relative to each other when thediaphragm is in use.

First layer 140 includes first and second sides 160, 162, and an outercircumference surface 164. First layer 140 is sized to engage an innersurface of first ring 152 and to form a seal there between. Since ring152 is open at its center, the first side 162 of first layer 140 isexposed at the center of ring 152. A valve connector 156 is insertmolded within layer 140 and configured to be coupled to a valve stem 158of the drive piston assembly 157 on the hydraulic drive side of the pump(see FIG. 1).

Second layer 142 includes first and second sides 170, 172 and an outercircumference surface 174. Second layer 142 is sized to seat withinsecond ring 154 and to form a seal there between (see FIG. 6). Becausesecond ring 154 is also open at its center, second surface 172 isexposed at the center of ring 154.

The first portion 146 of third layer 144 includes first and second sidesurfaces 180, 182 and an outer circumference surface 184. The secondportion 148 of third layer 144 includes first and second side surfaces190, 192 and an outer circumference surface 194. As shown in FIG. 7,first portion 146 has a larger diameter (D4) than the diameters D1, D2,D3 of respective layers 140, 142 and second portion 148. The largerdiameter D4 provides exposure of a portion of first portion 146 beyondthe outermost circumference surfaces of the first and second layers 140,142 and second portion 148 of diaphragm 122 a. A portion of conductivetrace 150 may then be formed on second side 182 such that a portion oftrace 150 is also exposed when the diaphragm layers are assembledtogether. This exposed portion of conductive trace 150 makes it possibleto easily connect electric leads 240, 242 at first and second ends 202,204 of the conductive trace pattern 200 (see FIGS. 6 and 8) withoutinterfering with the other diaphragm layers.

Second rim portion 154 may include first and second connector openings220, 222 and first and second connecting members 224, 226 at an outerface 230 for retaining the first and second leads 240, 242 in electricalcontact with first and second ends 202, 204 of the conductive trace 150.Although first and second connecting members 224, 226 are shown asthreaded fasteners in this embodiment, other types of fasteners orsecuring/retaining methods may be used to maintain electrical contactbetween the first and second leads 240, 242 and the conductive trace 150in other embodiments.

First rim member 152 includes an outer circumference surface 210 and arecessed portion 212 formed therein that is sized to engage a retainingclip 228 at an inner surface 232 of the second rim member 154.Engagement of recessed portion 212 with retaining clip 228 forms a snapfit connection between the first and second rim members 152, 154 inorder to retain the first, second and third layers 140, 142, 144together. In other embodiments, the first, second and third layers 140,142, 144 may be retained together with other means outside of the rimmembers shown such as, for example, rivets, fasteners, clamps, adhesivesthat are applied near an outer edge of the layers. In yet furtherembodiments, the layers 140, 142, 144 may be laminated, molded, adhered,heat welded, sonic welded or otherwise secured together across theprimary surfaces of the layers so as to form a unitary diaphragm memberwithout a separate ring or other retaining structure. However, asdiscussed above, the layers 140, 142, 144 are preferably independentlymovable relative to each other except at an outer edge where ringmembers 152, 154 secure the layers together.

The phrase “independently movable relative to each other” as used hereindefines the relative movement of the layers to each other as the layersare deformed during use. When the layers are bonded together acrosstheir entire primary surfaces, large shear forces are generated,particularly if the layers are made from different materials that havedifferent physical properties that allow them to stretch or deform atdifferent rates relative to each other. As will be discussed furtherbelow, some of the layers of the diaphragm 122 may have a differentmodulus of elasticity than other layers, which may create further shearforces. Furthermore, if the layers were secured together across theirprimary surfaces, a failure condition, such as a crack, in one layerwould easily propagate through to one or more of the other layers.

An advantage of having the layers 140, 142, 144 independently movablerelative to each other is that in most instances only one layer willfail at a time, thereby providing sufficient notice for the pump to beshut off before all of the layers fail. To further enhance theindependent movement of the layers 140, 142, 144, diaphragm 122 mayinclude a lubricant layer in between the layers, which also reducesfriction induced wear between the layers. Silicone grease is one examplelubricant that may be useful for this purpose, although anynon-conductive lubricant that is compatible with the elastomers beingused in the diaphragm may be used. The use of lubricants for reducingwear and friction between two members is well known in manyapplications, but is not known for use between elastomeric layers of apump diaphragm.

The conductive trace 150 shown in FIG. 8 is a continuous spiral withfirst and second ends 202, 204 exposed on second surface 182 near theouter circumference surface 184 of first portion 146 of third layer 144.This example pattern is only one of a variety of different patterns thatmay be used to provide the necessary sensitivity to changes inresistance of the pattern as the diaphragm 122 is deformed during use.The conductive trace 150 may be formed of a variety of differentmaterials or combination of material so long as trace 150 has electricalconductive properties and is resistant to high strain conditions, forexample, strain greater than 20%. These levels of strain typicallyexclude the possibility of using metallic substances such as copper andmetal alloys as trace materials. An example binder material forconductive trace 150 is an elastomeric substance such as silicone latex,or urethane that binds a conductive material such as carbon power tofirst portion 146. The conductive material provides the requiredelectrical conductive properties and has little effect on theelastomeric properties of the binder such that the conductive trace 150is resistant to strain greater than 20%.

The conductive material of conductive trace 150 may be supplied in theform of conductive inks and other substances that will bond well toelastomeric materials with a binder so long as the conductive materialmaintains electrical conductivity under high strain conditions. Silver,gold and other conductive metals maybe used in a powder form that iseffectly secured to first portion 146 with the binders discussed above.The conductive trace is preferably a continuous member with two freeends so that a power source can pass current through the conductivetrace and monitor the resistance of the conductive trace during use ofdiaphragm 122.

Conductive trace 150 may be formed using any application process that iscapable of providing a very thin layer of material, such as, forexample, silk screening, pad printing and spraying.

The first and second portions 146, 148 of third layer 144 are shown asseparate layers in the figures, but are ultimately bonded together insuch a way as to form a single layer in the final product with theconductive trace 150 embedded therein. First and second portions 146,148 are made of an elastomeric material such as silicone, buna,neoprene, TPR, or urethane that is resistant to high levels of straingreater than 20%. Preferably, the first and second portions 146, 148 aremade of the same material to improve the bond formed between the layers.In one method of bonding, the first layer 146 is formed using anyavailable process. Next, the conductive trace 150 is formed on firstlayer 146 using for example, one of the methods disclosed above. Next,the second portion 148 is bonded to the first portion 144 using aforming process such as molding, applying a liquid layer (e.g.,spraying), or laminating the two layers with an adhesive so as to formthe combined third layer 144 shown in FIG. 5. In this bonded state, theconductive trace 150 is preferably completely covered except at an outeredge of the first portion 146 (which exposed portion is covered by rimmembers 152, 154 when the diaphragm is assembled) so as to be protectedfrom exposure to the hydraulic and process fluids of pump 120. Theexposed portion of trace 150 near the outer circumference surface 184 offirst portion 146 is positioned within first and second rim members 152,154 so that electrical contact is limited to contact with first andsecond leads 240, 244 and second rim member 154.

In order to reduce the possibility of shorting or otherwise interferingwith the electrical signal in conductive trace 150, rim members 152, 154may be made of a non-conductive material such as fiberglass or a polymermaterial, or may include a layer of such non-conductive material at thepoints in which contact with conductive trace 150 are made whendiaphragm 122 is assembled. Protection of the conductive trace 150 fromexposure to the liquids of pump 120 significantly reduces thepossibility of failure being masked by the liquid conductivity.Furthermore, since the conductive trace is made from a very thin layerembedded within layer 144, only a very small cross section of conductivematerial is exposed when layer 144 is cut or broken. The conductivity ofthis small area contacting a conductive fluid is small compared to thetrace when it is intact, and therefore effectively eliminates the needfor ground fault detection for diaphragm 122.

Certain advantages of the present invention can be described using adiscussion of the various modes of diaphragm failure. The most commonfailure mode occurs when a failure in the hydraulic oil volume controlallows too much oil behind the diaphragm (at the first side 160 of firstlayer 140). In this situation, the diaphragm balloons forward until itcontacts openings in the first chamber 124 that cut the diaphragm. Inthe case where the layers of the diaphragm are independently movablefrom each other, no oil can leak through the diaphragm when only theouter (second layer 142) layer is cut because the first and secondlayers 140 and 144 remain intact and the failure in the second layerdoes not propagate to the first and third layers. Because the conductivetrace 150 is able to monitor mere changes in resistance that indicateboth actual failure and possibly initiation of a failure condition asopposed to rather than require a break in the conductive trace orexposure of the conductive trace to a conductive fluid determine failureof one of the diaphragm layers as known in the art, there may be abetter chance that the pump can be turned off before all of the layersfail.

Another type of diaphragm failure is fatigue. Fatigue can occur overtime as the diaphragm layer materials deteriorate and cracks begin toform. If this type of failure occurs in either the first or second layer140, 142, a change in resistance will occur either because more stressis added to the conductive trace. In the event that both of the firstand second layers 140, 142 fail at the same time, the third layer willstill provide fluid separation until failure of that layer occurs. Whenthe third layer 144 is the last layer to fail, the spike in resistancelevels due to failure of the first and second layers may be used toinitiate shut down of the pump preferably before the third layer failsso as to eliminate or at least significantly reduce the mixing of theprocess and hydraulic fluids in the pump.

A method of forming or manufacturing a pump diaphragm according toprinciples of the invention may include forming a first portion of anelastomeric layer, forming a conductive trace on the first portion ofthe elastomeric layer, and forming a second portion of the elastomericlayer on the first portion of elastomeric layer over a section of theconductive trace such that the first and second portions are integralwith each other and an outer periphery of the conductive trace isexposed. Further steps in such a method may include positioning theelastomeric layer between first and second layers to form a multi-layerdiaphragm. A still further step in this method may include applyinglubricant between the various layers of the diaphragm.

A method of detecting rupture of a diaphragm in a hydraulic pumpaccording to the principles of the invention may include positioning afirst elastomeric layer in contact with a process fluid to be pumped,positioning a second elastomeric layer in contact with a hydraulic oilof the pump, positioning a second elastomeric layer in contact with thehydraulic oil of the pump, positioning a third elastomeric layer betweenthe first and second layers, and applying and embedding a conductivetrace in the third layer. The method may also include applying anelectric current to the conductive trace and detecting variations inelectrical resistance in the conductive trace and generating a detectionsignal representative of changes in the electrical resistance. Thedetection signal may be used to provide a warning that there is a changein condition of the diaphragm, or may be used to automatically shut offthe hydraulic pump. Such a method may also include securing the layerstogether in such a way that the layers are independently movablerelative to each other when the diaphragm is deformed during use.

The above specification, examples and data provide a completedescription of the manufacture and use of the composition of theinvention. Since many embodiments of the invention can be made withoutdeparting from the spirit and scope of the invention, the inventionresides in the claims hereinafter appended.

1. A multi-layer diaphragm for use in a hydraulically driven pump, thediaphragm comprising: a first layer in contact with a pumped fluid; asecond layer in contact with a hydraulic oil of the pump; and a thirdlayer including a conductive trace, the third layer being positionedbetween the first and second layers, the third layer being independentlymovable relative to the first and second layers.
 2. The diaphragm ofclaim 1, wherein the third layer includes an elastomeric material. 3.The diaphragm of claim 1, wherein the conductive trace is embedded inthe third layer.
 4. The diaphragm of claim 1, wherein the first layerand second layer include buna rubber.
 5. The diaphragm of claim 1,wherein the third layer includes silicone.
 6. The diaphragm of claim 1,wherein the conductive trace layer includes carbon and silicone and iscapable of withstanding strain greater than 20%.
 7. The diaphragm ofclaim 1, wherein the conductive trace is formed as a continuous spiralwith opposing ends of the conductive trace being coupled to separateelectrical leads.
 8. The diaphragm of claim 1, further comprising firstand second rings configured to retain the first, second and third layerstogether.
 9. The diaphragm of claim 1, further comprising a lubricationlayer positioned between the third layer and at least one of the firstlayer and the second layer.
 10. The diaphragm of claim 1, wherein themolded third layer includes first and second portions bonded togetherwith the conductive trace positioned between first and second portions.11. The diaphragm of claim 10, wherein the first portion, the secondportion and the conductive trace each have an outer diameter, the outerdiameter of the first portion being greater than the outer diameter ofthe trace, and the outer diameter of the conductive trace being greaterthan the diameter of the second portion.
 12. The diaphragm of claim 1,wherein the first, second and third layers comprise elastomericmaterials and are configured to resist rupture under high strainconditions.
 13. A method of manufacturing a pump diaphragm, thediaphragm including an elastomeric layer and a conductive trace, themethod comprising the steps of: forming a first portion of theelastomeric layer, the first portion having a primary surface; formingthe conductive trace on the primary surface of the first portion of theelastomeric layer; and forming a second portion of the elastomeric layeron the primary surface of the first portion over a portion of theconductive trace; wherein the diaphragm further includes first andsecond layers, and the method further comprises positioning theelastomeric layer between the first and second layers.
 14. The method ofclaim 13, wherein the first and second portions are integral with eachother.
 15. The method of claim 13, wherein an outer periphery of theconductive trace is exposed for electrical connection.
 16. The method ofclaim 13, further comprising applying lubricant between the first andsecond layers and the elastomeric layer.
 17. The method of claim 13,wherein the conductive trace is configured as a continuous member havingfirst and second ends.
 18. The method of claim 13, further comprisingforming the conductive trace using silk screening.
 19. The method ofclaim 13, further comprising forming the elastomeric layer from amaterial comprising silicone.
 20. The method of claim 13, furthercomprising forming the conductive trace from a material comprisingsilicone and carbon.
 21. The method of claim 13, wherein the step offorming the second portion including a molding, heat bonding, orlaminating process.
 22. A method of detecting rupture of a diaphragm ina hydraulic pump that includes a first layer, a second layer, and athird layer, the third layer including a conductive trace, the methodcomprising the steps of: positioning the first layer in contact with afluid being pumped by the hydraulic pump; positioning the second layerin contact with a hydraulic oil of the hydraulic pump; positioning thethird layer between the first and second layers; applying an electriccurrent to the conductive trace; detecting variations in an electricalproperty in the conductive trace resulting from use of the diaphragm inthe hydraulic pump; shutting off the hydraulic pump when the variationsare within a predetermined range; and coupling the first, second andthird layer together at a periphery of the layers with center portionsof the layers being free to move relative to each other.
 23. The methodof claim 22, further comprising generating a detection signal, whereinthe detection signal indicates existence of a failure condition in atleast one of the first, second and third layers.
 24. The method of claim22, further comprising exposing the conductive trace only at an outerperiphery of the third layer and electrically connecting the exposedportion of the conductive trace to the electric current.
 25. The methodof claim 22, wherein the hydraulic pump further includes a lubricationlayer, and the method further comprises positioning the lubricationlayer between the third layer and at least one of the first layer andthe second layer.
 26. The method of claim 22, further comprisingembedding the conductive trace in the third layer.
 27. A multi-layerdiaphragm for use in a hydraulically driven pump, the diaphragmcomprising: a first layer having a first modulus of elasticity; a secondlayer having a second modulus of elasticity; a third layer positionedbetween the first and second layers and having a third modulus ofelasticity lower than the first and second modulus of elasticity, thethird layer including a conductive trace that is removed from contactwith fluids in the pump; wherein the conductive trace comprises anelastomeric material and is integral with the third layer.
 28. Thediaphragm of claim 27, wherein the conductive trace is exposed at anouter periphery of the third layer at a location.
 29. The diaphragm ofclaim 27, wherein the third layer includes silicone and the conductivetrace includes silicone and carbon.
 30. A hydraulically driven pump,comprising: a first chamber exposed to a pumped fluid; a second chamberconfigured to retain a hydraulic fluid; and a multi-layer diaphragmpositioned between the first and second chambers and including: a firstlayer in contact with the pumped fluid; a second layer in contact withthe hydraulic fluid; and a third layer including a conductive trace, thethird layer being positioned between the first and second layers andbeing movable relative to at least one of the first layer and the secondlayer.
 31. The pump of claim 30, wherein the third layer includes anelastomeric base material.
 32. The pump of claim 30, wherein theconductive trace comprises an elastomeric material and is embedded in abase material of the third layer.
 33. The pump of claim 30, wherein theelastomeric base material includes silicone and the conductive traceincludes carbon.
 34. The pump of claim 30, wherein changes in anelectrical resistance of the conductive trace indicate a failurecondition in one of the first, second and third layers.
 35. A method ofmanufacturing a pump diaphragm, the diaphragm including an elastomericlayer and a conductive trace, the method comprising the steps of:forming a first portion of the elastomeric layer, the first portionhaving a primary surface; forming the conductive trace on the primarysurface of the first portion of the elastomeric layer; and forming asecond portion of the elastomeric layer on the primary surface of thefirst portion over a portion of the conductive trace; wherein an outerperiphery of the conductive trace is exposed for electrical connection.36. A method of manufacturing a pump diaphragm, the diaphragm includingan elastomeric layer and a conductive trace, the method comprising thesteps of: forming a first portion of the elastomeric layer, the firstportion having a primary surface; forming the conductive trace on theprimary surface of the first portion of the elastomeric layer; forming asecond portion of the elastomeric layer on the primary surface of thefirst portion over a portion of the conductive trace; and forming theelastomeric layer from a material comprising silicone.
 37. A method ofdetecting rupture of a diaphragm in a hydraulic pump that includes afirst layer, a second layer, and a third layer, the third layerincluding a conductive trace, the method comprising the steps of:positioning the first layer in contact with a fluid being pumped by thehydraulic pump; positioning the second layer in contact with a hydraulicoil of the hydraulic pump; positioning the third layer between the firstand second layers; applying an electric current to the conductive trace;detecting variations in an electrical property in the conductive traceresulting from use of the diaphragm in the hydraulic pump; shutting offthe hydraulic pump when the variations are within a predetermined range;and embedding the conductive trace in the third material.
 38. Amulti-layer diaphragm for use in a hydraulically driven pump, thediaphragm comprising: a first layer having a first modulus ofelasticity; a second layer having a second modulus of elasticity; and athird layer positioned between the first and second layers and having athird modulus of elasticity lower than the first and second modulus ofelasticity, the third layer including a conductive trace that is removedfrom contact with fluids in the pump; wherein the third layer includessilicone and the conductive trace includes silicone and carbon.